WO1996003471A1 - Friction material - Google Patents

Friction material Download PDF

Info

Publication number
WO1996003471A1
WO1996003471A1 PCT/US1995/009096 US9509096W WO9603471A1 WO 1996003471 A1 WO1996003471 A1 WO 1996003471A1 US 9509096 W US9509096 W US 9509096W WO 9603471 A1 WO9603471 A1 WO 9603471A1
Authority
WO
WIPO (PCT)
Prior art keywords
friction material
weight
fibers
iron powder
friction
Prior art date
Application number
PCT/US1995/009096
Other languages
English (en)
French (fr)
Inventor
Christopher C. Shepley
David R. Carter
Original Assignee
Brake Pro, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Brake Pro, Inc. filed Critical Brake Pro, Inc.
Priority to MX9605966A priority Critical patent/MX9605966A/es
Priority to EP95927280A priority patent/EP0772658A4/en
Priority to AU31360/95A priority patent/AU3136095A/en
Publication of WO1996003471A1 publication Critical patent/WO1996003471A1/en

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02Composition of linings ; Methods of manufacturing
    • F16D69/025Compositions based on an organic binder
    • F16D69/026Compositions based on an organic binder containing fibres

Definitions

  • This invention relates to friction materials for improving wear resistance and reducing noise levels between high load bearing friction surfaces, and more particularly, for mechanical structures such as brakes, couplings, clutches and transmission systems, among others.
  • Friction materials have been utilized for a number of years in industries such as the automotive component industry.
  • Materials used in such friction coatings include, for example, graphite, ceramic powders, metal or metal oxide powders, heat hardenable phenolic resins, asbestos fibers, glass and carbon fibers, aramid fibers, steel wool, bentonite, mica and diatomaceous materials, among others.
  • Such friction materials are used to form molded friction bearing components.
  • United States Patent No. 5,004,497 which issued April 2, 1991 to Shibata et al.
  • aramid fibers preferably consist of para-aramid fibers and/or a combination of chopped aramid fibers and fibrillar aramid fibers
  • Another friction material is disclosed in United States Patent No. 4,777,193 which issued October 11, 1988 to Kani.
  • the Kani patent discloses a molded resin composite of friction material for use in clutches of automobiles or similar parts, wherein the composition comprises inert fiber, a resin binder, an organic filler, and an inert filler wherein the inert filler contains zirconium silicate in an amount of from between about 0.1 to about 5.0% by volume based on 100% by volume of the total composition.
  • Still another friction material is disclosed in United States Patent No. 4,654,381 which issued March 31, 1987 to Kang et al.
  • compositions disclosed are characterized by the addition of any one of more than two cermet powders selected from the group consisting of (a) a powdered cermet comprising 75 to 50% by weight of a blended carbonaceous material and 25 to 50% by weight of the stainless steel alloyed iron; (b) a powdered cermet comprising 75 to 50% by weight of a blended carbonaceous material and 25 to 50% by weight of tungsten alloyed iron and/or molybdenum alloyed iron; and (c) a powdered cermet comprising 75 to 50% by weight of a blended carbonaceous material and 25 to 50% by weight of metallic iron; wherein the blended carbonaceous material is a mixture of 90 to 70% by weight of oil coats and 10 to 30% by weight of graphite with the cermet powder being added to the composition in an amount of 15 to 40% by weight based on the total weight of the composition.
  • cermet powders selected from the group consisting of (a) a powdered cermet comprising 75 to 50% by weight of
  • a friction material which includes the incorporation of metal sulfides alloyed with iron powders, wherein the resulting alloys are added to various metal based friction material compounds to provide a friction material with enhanced friction stability.
  • This improved friction stability will generally be reflected in greater wear resistance along both the friction bearing surface and the opposing contact surface.
  • metal sulfides which have proven useful, manganese sulfide has proven to be particularly useful.
  • a base friction material comprises between about 85% to about 99% by weight of a compound including varying amounts of pulp, steel fibers, iron powders, carbon, inert fillers and phenolic resins and about 1% to about 15% by weight of a metal sulfide - iron powder alloy.
  • the metal sulfides which are alloyed with iron powder using known techniques generally include ZnS, FeS, MoS 2 , CuS ⁇ TiS, CdS,Sb 2 S 3 , MnS, CoS, Co 3 S 4 , CaS, BaS, SrS, FeS 2 , ZrS 2 ,Cu 2 S, Ni 3 S 2 , NiS, Ni 3 S 4 , MnS ⁇ CoS 2 , Co 2 S 3 , SnS.
  • the constituents of the base friction material are typically commercially available from a number of different sources.
  • the metal sulfide-iron powder alloy can be introduced either as is or in the form of an admixture with other materials such as solid lubricants including antimony sulfide and aluminum phosphate, among others.
  • a friction material for use in forming friction bearing components comprises a base friction material including a mixture of pulp, steel fibers, iron powder, carbon, inert fillers and binders and an admixture of a metal sulfide-iron powder alloy.
  • a base friction material including a mixture of pulp, steel fibers, iron powder, carbon, inert fillers and binders and an admixture of a metal sulfide-iron powder alloy.
  • An important aspect of the present invention is that the metal sulfide-iron powder alloy can be added in an amount up to about 15% by weight.
  • the binders useful in accordance with the teachings of the present invention are mainly composed of resins prepared through condensation of one or more types of phenol or cresol, with formaldehyde based compounds.
  • various modified phenolic resins are useful under the present invention such as those modified with various vegetable oils or epoxy compounds, unmodified phenolic resins are preferred.
  • the amount of included within the base friction material includes between about 8% to about 30% by weight of final composition, more preferably between about 10% to about 25% and highly preferably between about 12% to about 20% by weight. In general, amounts below 8% by weight give rise to a relatively weak material and in contrast weight percentages over about 30% affect the acceptable porosity and anti-fading properties of the friction material.
  • the inert fillers of the present invention are typically present in the range of between about 5% to about 20% by weight of the final composition. Under a more preferred embodiment the range is between about 7% to about 16% by weight, and, under a highly preferred embodiment the range is between about 8% to about 14% by weight of the final composition. While a number of commercially available inert fillers are useful under the present invention, barytes, clays, whiting and talc have proven to be particularly useful.
  • the amount of carbon utilized under the present invention ranges from between about 6% to about 30% by weight. Under more highly preferred embodiments this range is from about 10% by weight to about 25% by weight, and under the most preferred embodiments this range is from 12% to about
  • fibrous materials are also included within the composition of the present invention.
  • the acceptable fibers are one or more fibers including but not limited to glass fibers, ceramic fibers, silica fibers, aluminum fibers, carbon fibers, metallic fibers, mineral fibers and mixtures thereof.
  • Highly preferred forms of fibers include aramid and acrylic based reticulated fibers, otherwise known as pulp.
  • Two forms of aramid fibers which are highly preferred, include KEVLAR* fibers available from E.I.
  • Another highly preferred form of fibrous material useful under the present invention is steel fibers such as commercial grade steel wool. While commercial grade steel wool is readily available from a number of different sources the steel fibers used to prepare example formulations under the present invention were purchased from American
  • the amount of fibrous material utilized in accordance with the teachings of the present invention ranges from about 10% to about 65% by weight of the overall composition. Under more preferred embodiments this amount ranges from about 20% to about 50% and under highly preferred embodiments the amount of fibrous material utilized will typically range from about 30% to about 45% by weight of the overall composition.
  • the various iron powders which are useful in preparing the friction material of the present invention those known as LD-80, P100 and R12 which are available from Pyron, Inc. of Niagara Falls, New York have proven to be particularly useful.
  • the iron metal powder utilized will have a particle size ranging from between about 35 and about 325 mesh, as tested under a common mesh screen analysis.
  • the iron powder included within the base friction material is generally present in an amount between about 10% to about 35% based on the overall weight of the composition. More preferably, the amount of iron powder utilized in the base friction material is from about 12% to about 30% and still more preferably from about 15% to about 25% based on the total weight of the final friction material composition.
  • a metal sulfide-iron powder alloy is formed by conventional alloying techniques and added to the base friction material to complete the composition.
  • MP37R which is available from DOMFER Metal Powders, Ltd. of Montreal, Quebec, Canada has proven to be particularly useful.
  • the metal sulphide-iron powder utilized will have a particle size of between about 60 and about 325 mesh, as tested under a common mesh screen analysis.
  • This metal sulfide-iron powder alloy is typically present in an amount of between about 1% to about 15% based on a total weight percentage of the final composition. Under preferred embodiments this amount is typically in the range of between 2% to about 12% and under highly preferred embodiments from between about 3% to about 8% by weight of the final composition.
  • the method of manufacturing a friction bearing component such as an automotive vehicle brake pad using the compositions according to the teaching of the present invention involve a conventional manufacturing process known as compression molding. Initially, the base friction materials including the fibrous materials, carbonaceous materials, inert fillers, iron powder and resin type powdery binders are admixed under continuous stirring within the mixing vessel. Subsequently, the metal sulfide-iron powder alloy is added to the base material and the overall composition is thoroughly mixed. Once the composition is fully mixed an amount of the material sufficient to mold the desired component is pre-shaped by molding under a pressure of approximately 150 kg/cm 2 at room temperature within a press mold.
  • the preform molded product is further molded by subjecting it to pressure of 400 kg/cm 2 at a temperature of approximately 150 C C for approximately 8 minutes. Finally, the molding is released from the die and heated for approximately 12 hours at a temperature of 180°C. After the heated molding cools to approximately room temperature and any necessary final machining and assembly is done, the component may be applied to the automotive vehicle.
  • the incidence of objectionable noise increases as the test progresses. That is, the lower noise rating values (i.e. more noise) are usually recorded towards the end of the test. While average noise ratings are shown, the inclusion of the metal sulphide-iron alloy in the formulation suppresses the rate of increase in objectionable noise incidence with time, as evidenced by the smaller difference between the average and worst noise recorded for those formulas containing the metal sulphide-iron alloy as compared with those formulas where the metal sulphide-iron alloy is absent.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Mechanical Operated Clutches (AREA)
PCT/US1995/009096 1994-07-22 1995-07-19 Friction material WO1996003471A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
MX9605966A MX9605966A (es) 1994-07-22 1995-07-19 Material de friccion.
EP95927280A EP0772658A4 (en) 1994-07-22 1995-07-19 FRICTION MATERIAL
AU31360/95A AU3136095A (en) 1994-07-22 1995-07-19 Friction material

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/278,748 US5501728A (en) 1994-07-22 1994-07-22 Friction material
US08/278,748 1994-07-22

Publications (1)

Publication Number Publication Date
WO1996003471A1 true WO1996003471A1 (en) 1996-02-08

Family

ID=23066186

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1995/009096 WO1996003471A1 (en) 1994-07-22 1995-07-19 Friction material

Country Status (5)

Country Link
US (1) US5501728A (es)
EP (1) EP0772658A4 (es)
AU (1) AU3136095A (es)
MX (1) MX9605966A (es)
WO (1) WO1996003471A1 (es)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DK101296A (da) * 1996-09-17 1998-03-18 Roulunds Fabriker As Bremsebelægningsmateriale og fremgangsmåde til fremstilling af samme samt bremsebelægning
US6264718B1 (en) * 2000-05-26 2001-07-24 Kobelco Metal Powder Of America, Inc. Powder metallurgy product and method for manufacturing the same
US6391083B1 (en) * 2000-11-09 2002-05-21 Kobeico Metal Powder Of America, Inc. Mixture for powder metallurgy product and method for producing the same
US7504920B2 (en) * 2001-09-26 2009-03-17 Tekonsha Engineering Company Magnetic brake assembly
US20040146702A1 (en) * 2003-01-29 2004-07-29 Xinming Shao Pure iron fiber based friction material product
US7588609B2 (en) * 2004-07-30 2009-09-15 Climax Engineered Materials, Llc Friction material compositions and additives
US20060151268A1 (en) * 2005-01-12 2006-07-13 Sunil Kesavan Copper-free non-asbestos organic friction material
JP6480265B2 (ja) * 2015-05-27 2019-03-06 株式会社神戸製鋼所 鉄基粉末冶金用混合粉及びその製造方法並びに焼結体及びその製造方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4178278A (en) * 1978-03-01 1979-12-11 Johns-Manville Corporation Friction material for railroad service
US5004497A (en) * 1988-09-12 1991-04-02 Honda Giken Kogyo Kabushiki Kaisha Friction material

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1845855A (en) * 1928-10-05 1932-02-16 Ura U Ulam Motor vehicle starting attachment
US2052779A (en) * 1932-12-05 1936-09-01 American Brakeblok Corp Friction element composition
DE1089161B (de) * 1955-02-17 1960-09-15 Lemfoerder Metallwarengesellsc Herstellung von Polyurethan-Elastomeren mit niedrigem Reibungskoeffizienten nach demGiessverfahren
US4093578A (en) * 1976-02-27 1978-06-06 Jury Nikolaevich Vasiliev Self-lubricating antifriction material
JPS55138055A (en) * 1979-04-12 1980-10-28 Akebono Brake Ind Co Ltd Sintered alloy having lubrication function, preparation of the same, and friction mate-material using the same
JPS5713144A (en) * 1980-06-25 1982-01-23 Hitachi Ltd High-hardness and high-density sintered alloy and its manufacture
GB8405645D0 (en) * 1984-03-03 1984-04-04 Ferodo Ltd Friction materials
KR860000984A (ko) * 1984-07-20 1986-02-22 박승문 자동차 바퀴에 장착된 발전장치
GB8426601D0 (en) * 1984-10-20 1984-11-28 Nuturn Corp Friction materials
JPS61115987A (ja) * 1984-11-12 1986-06-03 Sumitomo Electric Ind Ltd スチ−ルフアイバ−を用いた摩擦材

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4178278A (en) * 1978-03-01 1979-12-11 Johns-Manville Corporation Friction material for railroad service
US5004497A (en) * 1988-09-12 1991-04-02 Honda Giken Kogyo Kabushiki Kaisha Friction material

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP0772658A4 *

Also Published As

Publication number Publication date
EP0772658A4 (en) 1997-11-12
MX9605966A (es) 1997-12-31
EP0772658A1 (en) 1997-05-14
US5501728A (en) 1996-03-26
AU3136095A (en) 1996-02-22

Similar Documents

Publication Publication Date Title
EP0093673B1 (en) A sintered iron base friction material
EP0184708B2 (en) Friction material
JPS5918429B2 (ja) 有機摩擦材料
US4672082A (en) Friction material using steel fibers
EP0000841B1 (en) Improvements in or relating to friction materials
JPS6317872B2 (es)
US4388423A (en) Friction lining material
US2863211A (en) Friction assembly
US5501728A (en) Friction material
EP0740745B1 (en) FRICTION MATERIAL FOR USE WITH Al.ALLOY ROTOR
US7588609B2 (en) Friction material compositions and additives
EP1482204A1 (en) Friction material
US4665108A (en) Friction material using iron powder
JPH06346932A (ja) 摩擦材
EP0443550B1 (en) Asbestos-free brake lining
US4461643A (en) Friction lining material
US4777193A (en) Molded resin composition of frictional material for use in clutches
US4954536A (en) Brake-friction material
CA2208898C (en) Friction material
KR100558706B1 (ko) 비석면계 마찰재
JPH04106183A (ja) 非石綿系摩擦材
US4487729A (en) Friction lining material
JPH04306288A (ja) 非石綿系摩擦材
RU2072372C1 (ru) Полимерная фрикционная композиция
GB2258657A (en) Friction materials for railway brake pads

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AM AT AU BB BG BR BY CA CH CN CZ DE DK EE ES FI GB GE HU IS JP KE KG KP KR KZ LK LR LT LU LV MD MG MN MW MX NO NZ PL PT RO RU SD SE SG SI SK TJ TM TT UA UG US UZ VN

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): KE MW SD SZ UG AT BE CH DE DK ES FR GB GR IE IT LU MC NL PT SE BF BJ CF CG CI CM GA GN ML MR NE SN TD TG

DFPE Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101)
121 Ep: the epo has been informed by wipo that ep was designated in this application
WWE Wipo information: entry into national phase

Ref document number: PA/a/1996/005966

Country of ref document: MX

WWE Wipo information: entry into national phase

Ref document number: 1995927280

Country of ref document: EP

REG Reference to national code

Ref country code: DE

Ref legal event code: 8642

WWP Wipo information: published in national office

Ref document number: 1995927280

Country of ref document: EP

NENP Non-entry into the national phase

Ref country code: CA

WWW Wipo information: withdrawn in national office

Ref document number: 1995927280

Country of ref document: EP